Diesel multiple unit trains wheel set maintenance modelling, simulation and optimization

B M Alkali, V Orsi

    Research output: Chapter in Book/Report/Conference proceedingConference contribution

    Abstract

    This paper presents the modelling and simulation of Class 170 wheel sets for a fleet of trains in Scotland. A description of the wheel set defect challenges and the evaluation of the maintenance practices of the wheel sets are presented in this paper. An Alternative Non Destructive Testing (NDT), Remote Condition Monitoring and maintenance optimisation of the Class 170 wheelsets of the trains is discussed. All Class 170 wheelset associated failure modes and maintenance requirements are analysed using the Reliability Centred Maintenance (RCM) approach. The failure modes identified Maintenance optimisation simulations are conducted using specialist RCMCost Availability Workbench (ISOGPRAPH) simulation software by fitting a Weibull model to the data. An optimum cost effective preventive maintenance schedule and periodicity is achieved and as a result contribute to 21% - 50% labor cost savings over a period of 3 years. The proposed evaluation technique to eliminate intrusive Ultrasonic Axle Testing (UAT) through the alternative NDT technology to detect sub surface cracks or flaws did not identify any ideal solution for a high maintenance turnaround environment. However, remote Wheel Slip Protection (WSP) condition monitoring solutions present the opportunity to proactively identify wheel slip events in-service that contribute to the early manifestation of wheel tread defects. This identification system enables the maintenance manager to optimise maintenance planning, improve fleet availability, maintenance efficiency, and operational safety, maintain quality and increase wheel set functional life.
    Original languageEnglish
    Title of host publicationProceedings of the Third International Conference on Railway Technology: Research, Development and Maintenance
    EditorsJ Pombo
    Place of PublicationStirlingshire
    PublisherCivil-Comp Press
    ISBN (Print)9781905088652
    DOIs
    Publication statusPublished - 8 Apr 2016

    Publication series

    NameCivil-Comp Proceedings
    Volume110
    ISSN (Print)1759-3433

    Fingerprint

    Wheels
    Computer simulation
    Condition monitoring
    Nondestructive examination
    Defects
    Failure modes
    Availability
    Preventive maintenance
    Axles
    Costs
    Identification (control systems)
    Managers
    Ultrasonics
    Personnel
    Cracks
    Planning
    Testing

    Keywords

    • condition monitoring
    • wheel set
    • non-destructive testing
    • maintenance optimisation
    • simulation

    Cite this

    Alkali, B. M., & Orsi , V. (2016). Diesel multiple unit trains wheel set maintenance modelling, simulation and optimization. In J. Pombo (Ed.), Proceedings of the Third International Conference on Railway Technology: Research, Development and Maintenance (Civil-Comp Proceedings; Vol. 110). Stirlingshire: Civil-Comp Press. https://doi.org/10.4203/ccp.110.284
    Alkali, B M ; Orsi , V. / Diesel multiple unit trains wheel set maintenance modelling, simulation and optimization. Proceedings of the Third International Conference on Railway Technology: Research, Development and Maintenance. editor / J Pombo. Stirlingshire : Civil-Comp Press, 2016. (Civil-Comp Proceedings).
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    abstract = "This paper presents the modelling and simulation of Class 170 wheel sets for a fleet of trains in Scotland. A description of the wheel set defect challenges and the evaluation of the maintenance practices of the wheel sets are presented in this paper. An Alternative Non Destructive Testing (NDT), Remote Condition Monitoring and maintenance optimisation of the Class 170 wheelsets of the trains is discussed. All Class 170 wheelset associated failure modes and maintenance requirements are analysed using the Reliability Centred Maintenance (RCM) approach. The failure modes identified Maintenance optimisation simulations are conducted using specialist RCMCost Availability Workbench (ISOGPRAPH) simulation software by fitting a Weibull model to the data. An optimum cost effective preventive maintenance schedule and periodicity is achieved and as a result contribute to 21{\%} - 50{\%} labor cost savings over a period of 3 years. The proposed evaluation technique to eliminate intrusive Ultrasonic Axle Testing (UAT) through the alternative NDT technology to detect sub surface cracks or flaws did not identify any ideal solution for a high maintenance turnaround environment. However, remote Wheel Slip Protection (WSP) condition monitoring solutions present the opportunity to proactively identify wheel slip events in-service that contribute to the early manifestation of wheel tread defects. This identification system enables the maintenance manager to optimise maintenance planning, improve fleet availability, maintenance efficiency, and operational safety, maintain quality and increase wheel set functional life.",
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    Alkali, BM & Orsi , V 2016, Diesel multiple unit trains wheel set maintenance modelling, simulation and optimization. in J Pombo (ed.), Proceedings of the Third International Conference on Railway Technology: Research, Development and Maintenance. Civil-Comp Proceedings, vol. 110, Civil-Comp Press, Stirlingshire. https://doi.org/10.4203/ccp.110.284

    Diesel multiple unit trains wheel set maintenance modelling, simulation and optimization. / Alkali, B M; Orsi , V.

    Proceedings of the Third International Conference on Railway Technology: Research, Development and Maintenance. ed. / J Pombo. Stirlingshire : Civil-Comp Press, 2016. (Civil-Comp Proceedings; Vol. 110).

    Research output: Chapter in Book/Report/Conference proceedingConference contribution

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    AB - This paper presents the modelling and simulation of Class 170 wheel sets for a fleet of trains in Scotland. A description of the wheel set defect challenges and the evaluation of the maintenance practices of the wheel sets are presented in this paper. An Alternative Non Destructive Testing (NDT), Remote Condition Monitoring and maintenance optimisation of the Class 170 wheelsets of the trains is discussed. All Class 170 wheelset associated failure modes and maintenance requirements are analysed using the Reliability Centred Maintenance (RCM) approach. The failure modes identified Maintenance optimisation simulations are conducted using specialist RCMCost Availability Workbench (ISOGPRAPH) simulation software by fitting a Weibull model to the data. An optimum cost effective preventive maintenance schedule and periodicity is achieved and as a result contribute to 21% - 50% labor cost savings over a period of 3 years. The proposed evaluation technique to eliminate intrusive Ultrasonic Axle Testing (UAT) through the alternative NDT technology to detect sub surface cracks or flaws did not identify any ideal solution for a high maintenance turnaround environment. However, remote Wheel Slip Protection (WSP) condition monitoring solutions present the opportunity to proactively identify wheel slip events in-service that contribute to the early manifestation of wheel tread defects. This identification system enables the maintenance manager to optimise maintenance planning, improve fleet availability, maintenance efficiency, and operational safety, maintain quality and increase wheel set functional life.

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    Alkali BM, Orsi V. Diesel multiple unit trains wheel set maintenance modelling, simulation and optimization. In Pombo J, editor, Proceedings of the Third International Conference on Railway Technology: Research, Development and Maintenance. Stirlingshire: Civil-Comp Press. 2016. (Civil-Comp Proceedings). https://doi.org/10.4203/ccp.110.284